CONNECTING ELEMENT AND COMPONENT CONNECTION AND METHOD FOR THE PRODUCTION THEREOF

Abstract

The invention relates to a connecting element (10) having a hollow-cylindrical shaft (12) and a drive (16), via which the shaft (12) can be driven in a direction of rotation, wherein the hollow-cylindrical shaft (12) has at least one free end, wherein the drive (16) is arranged opposite the free end, wherein a hollow space is formed by the hollow-cylindrical shaft (12). The invention is characterized in that driver structures (22) acting in the circumferential direction of the hollow-cylindrical shaft (12) are arranged in the hollow space, which, projected on the lateral surface, are arranged to extend in the setting direction on the lateral surface, rectilinearly parallel to the element mid-axis (M) or with an angular deviation of at most 20° with respect to the element mid-axis (M), and/or are arranged at the end on the drive side.

Claims

1-28. (canceled)

29. Connecting element (10, 30, 40, 58, 78) having a hollow-cylindrical shaft (12, 42, 76) and a drive (16), via which the shaft (12, 42, 76) can be driven in a direction of rotation, wherein the hollow-cylindrical shaft (12, 42, 76) has at least one free end, wherein the drive (16, 48) is arranged opposite the free end, wherein a hollow space is formed by the hollow-cylindrical shaft (12, 42, 76), driver structures (22, 32) acting in the circumferential direction of the hollow-cylindrical shaft (12) are arranged in the hollow space, which structures are arranged to extend on the lateral surface (20) in the setting direction in a manner rectilinearly parallel to the element mid-axis (M) or with an angular deviation of at most 20° with respect to the element mid-axis (M) projected on the lateral surface (20) and/or are arranged at the end on the drive side.

30. Connecting element according to claim 29, characterized in that the connecting element has a shoulder (18, 44) that is connected to the shaft (12, 42, 76).

31. Connecting element according to claim 30, characterized in that the shoulder (18, 44) is part of a head (46) that forms the end of the shaft.

32. Connecting element according to claim 30, characterized in that the shoulder (18) is designed as an annular shoulder (18) having a central recess (24), the smallest diameter of which corresponds to at least the inner diameter of the hollow-cylindrical shaft (12).

33. Connecting element according to claim 32, characterized in that the central recess (24) increases in diameter as seen in a direction away from the free end of the shaft (12).

34. Connecting element according to claim 30, characterized in that the drive (16, 48) is formed on the head (46) and/or on the annular shoulder (18).

35. Connecting element according to claim 31, characterized in that the driver structures arranged at the end on the drive side are formed into the underside of the head.

36. Connecting element according to claim 29, characterized in that the driver structures, which are arranged to extend on the lateral surface in a manner rectilinearly parallel to the element mid-axis or with an angular deviation of 20° with respect to the element mid-axis projected onto the lateral surface, are provided in the form of raised portions (22).

37. Connecting element according to claim 29, characterized in that the driver structures, which are arranged to extend on the lateral surface in a manner rectilinearly parallel to the element mid-axis or with an angular deviation of 20° with respect to the element mid-axis projected onto the lateral surface, are provided in the form of grooves (32).

38. Connecting element according to claim 29, characterized in that it is provided with a cutting edge, in particular in the form of a chamfer (26), at its free end.

39. Connecting element according to claim 29, characterized in that it is made of an iron metal, in particular steel.

40. Method for the production of a component connection between two component layers (52, 54; 72, 74), comprising a base layer (52, 72) and a top layer (54, 74) arranged thereon, wherein a connecting element (10, 30, 40, 58, 78) having a hollow-cylindrical shaft (12, 42, 76) is driven into the top layer (54, 74) under rotation and an axial force, with a slug (62, 82) being cut out of the top layer (54, 74) by the interior of the shaft and being entrained by the connecting element as it rotates, the slug (62, 82) being welded to the base layer (52, 72) under rotation and contact pressure, whereupon the connecting element (10, 30, 40, 58, 78) is at least partially pressed into the base layer (52, 72).

41. Method according to claim 40, characterized in that the speed at which the connecting element (10, 30, 40, 58, 78) is driven until the slug (62, 82) is welded in place is at least 2,000 rpm.

42. Method according to claim 41, characterized in that a first process step is carried out in which the connecting element (10, 30, 40, 58, 78) is applied at an appropriate speed and axial force for cutting so as to reliably prevent deformation of the connecting element (10, 30, 40, 58, 78) when cutting out the slug (62, 82) until the connecting element (10, 30, 40, 58, 78) has reached the surface of the base layer (52, 72).

43. Method according to claim 42, characterized in that a second process step is carried out in which the cut-out slug (62, 82) is welded to the base layer (52, 72) by applying an axial force for welding to the slug (62, 82) while continuing rotation, with the axial force applied by the tool for welding being increased compared to the axial force applied for cutting.

44. Method according to claim 43, characterized in that the connecting element (10, 30, 40, 58, 78) has a head which terminates the hollow-cylindrical shaft (12, 42, 76) at its end opposite the direction of its insertion, said head of the connecting element applying the axial force for welding to the slug (62, 82).

45. Method according to claim 43, characterized in that the connecting element (10, 30, 40, 58, 78) is open against the direction of its insertion, at least over the inner surface of the hollow-cylindrical shaft (12, 42, 76), and the contact pressure is applied to the slug (62, 82) by a setting tool that also applies the contact pressure to the connecting element (10, 30, 40, 58, 78).

46. Method according to claim 43, characterized in that a third process step is carried out in which the welding axial force on the connecting element (10, 30, 40, 58, 78) and the slug (62, 82) at decreasing speed with increased axial rivet force compared to the welding axial force to produce the positive connection in the axial direction with the base layer (52, 72) and/or the top layer (54, 74).

47. Method according to claim 46, characterized in that the connecting element (10, 30, 40, 58, 78) is open against the direction of its insertion, at least over the inner surface of the hollow-cylindrical shaft (12, 42, 76), and the contact pressure is applied to the slug (62, 82) by a setting tool that also applies the contact pressure to the connecting element (10, 30, 40, 58, 78), in which process the end of the slug (62, 82) located opposite the direction of its insertion is flared.

48. Component connections comprising a base layer (52, 72) and at least one top layer (54, 74) arranged thereon, and a connecting element (10, 30, 40, 58, 78) with a hollow-cylindrical shaft (12, 42, 76) and a drive adapted to drive the shaft (12, 42, 76) in the direction of rotation, wherein the hollow-cylindrical shaft has at least one free end, wherein the drive is arranged opposite the free end, wherein a hollow space is formed by the hollow-cylindrical shaft (12, 42, 76), wherein part of the hollow-cylindrical shaft (12, 42, 76) is completely surrounded by the base layer (52, 72), wherein a slug (62, 82) is cut out of the top layer (54, 74) by the interior of the hollow-cylindrical shaft (12, 42, 76), characterized in that within the hollow space there is a material connection between the base layer and the slug (62, 82).

49. Component connection according to claim 48, characterized in that driver structures acting in the circumferential direction of the hollow-cylindrical shaft are arranged in the hollow space, which driver structures are enclosed by the material of the slug.

50. Component connection according to 48, characterized in that a positive connection is produced acting in the axial direction in that radially displaced material of the slug (62, 82) projecting from the top layer (54, 74) forms a collar on the top layer (54, 74) and/or on the connecting element (10, 30, 40, 58, 78).

51. Component connection according to claim 48, characterized in that a positive connection acting in the axial direction is produced by a positive fit of the connecting element (10, 30, 40, 58, 78) with the top layer (54, 74) and a positive fit of the connecting element (10, 30, 40, 58, 78) of the base layer.

52. Component connection according to claim 48, characterized in that the positive connection with the base layer (52, 72) is produced by flaring the free end of the connecting element (10, 30, 40, 58, 78) that extends in the direction of insertion.

53. Component connection according to claim 48, characterized in that the connecting element (10, 30, 40, 58, 78) has a higher strength than the base layer (52, 72) and the top layer (54, 74).

54. Component connection according to claim 48, characterized in that the base layer and the top layer (54, 74) are made of a non-ferrous metal and the connecting element is made of a steel or a non-ferrous metal.

55. Component connection according to claim 48, characterized in that the base layer and the top layer (54, 74) are made of a thermoplastic material and the connecting element is made of a plastic or a steel or a non-ferrous metal.

56. Component connection according to claim 48, characterized in that the connecting element (10, 30, 40, 58, 78) having a hollow-cylindrical shaft (12, 42, 76) and a drive (16), via which the shaft (12, 42, 76) can be driven in a direction of rotation, wherein the hollow-cylindrical shaft (12, 42, 76) has at least one free end, wherein the drive (16, 48) is arranged opposite the free end, wherein a hollow space is formed by the hollow-cylindrical shaft (12, 42, 76), driver structures (22, 32) acting in the circumferential direction of the hollow-cylindrical shaft (12) are arranged in the hollow space, which structures are arranged to extend on the lateral surface (20) in the setting direction in a manner rectilinearly parallel to the element mid-axis (M) or with an angular deviation of at most 20° with respect to the element mid-axis (M) projected on the lateral surface (20) and/or are arranged at the end on the drive side.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0044] In the drawings,

[0045] FIG. 1 is a lateral view of a connecting element according to the invention;

[0046] FIG. 1A is a sectional view of a connecting element according to the invention as seen in FIG. 1;

[0047] FIG. 1B is a view of a cross-section taken through the shaft of the connecting element of FIG. 1;

[0048] FIG. 2 is a perspective view of the connecting element of FIG. 1 with the collar as seen from above;

[0049] FIG. 3 is a lateral view of another embodiment of the connecting element according to the invention;

[0050] FIG. 3A is a sectional view of a connecting element as seen in FIG. 3;

[0051] FIG. 3B is a view of a cross-section taken through the shaft of the connecting element of FIG. 3;

[0052] FIG. 4 is a lateral view of another connecting element according to the invention;

[0053] FIG. 4A is a sectional view of a connecting element as seen in FIG. 4;

[0054] FIG. 4B is a view of a cross-section taken through the connecting element of FIG. 4;

[0055] FIG. 5A is a view of a first step in the production of a component connection using a connecting element according to the invention as shown in FIG. 1;

[0056] FIG. 5B is a view of a second step in the production of a component connection using a connecting element according to the invention as shown in FIG. 1;

[0057] FIG. 5C is a view of a third step in the production of a component connection using a connecting element according to the invention as shown in FIG. 1;

[0058] FIG. 6A is a view of a first step in the production of a component connection using a connecting element according to the invention as shown in FIG. 4;

[0059] FIG. 6B is a view of a second step in the production of a component connection using a connecting element according to the invention as shown in FIG. 4, and

[0060] FIG. 6C is a view of a third step in the production of a component connection using a connecting element according to the invention as shown in FIG. 4.

[0061] The lateral view of FIG. 1 shows a connecting element 10 according to the invention for connecting a base layer to a top layer arranged thereon. The connecting element 10 comprises a hollow-cylindrical shaft 12 having a free end 14 and having a drive 16 arranged on the end of the hollow-cylindrical shaft 12 opposite its free end 14. The drive 16 is designed as an external drive and has corresponding positive locking structures. The connecting element 10 will be described in more detail below with reference to the following figures.

[0062] FIG. 1A is a sectional view of the connecting element 10. Illustrated in this view is a hollow-cylindrical shaft 12 and a collar 18 with a drive 16 formed into it. The hollow-cylindrical shaft 12 has ribs 22 on its inner lateral surface 20, which ribs in this example extend over the entire length of the hollow-cylindrical shaft 12. The ribs 22 of the connecting element 10 serve to entrain a slug removed from the top layer during the rotational movement of the connecting element 10. Entraining the slug in the rotational movement of the connecting element allows the slug to be integrally bonded to the base layer in a friction welding process.

[0063] The free end 14 of the hollow-cylindrical shaft 12 is provided with a chamfer 26 to facilitate penetration of the top layer and, if necessary, to allow the hollow-cylindrical shaft 12 to be flared in a deformation process in the base layer.

[0064] This view also shows the ribs 22 which run parallel to the element mid-axis M of the connecting element 10.

[0065] FIG. 1B is a view of a cross-section taken along lines B-B through the shaft 12 of the connecting element 10. As seen in this view, the present embodiment has three ribs 22 arranged on the lateral surface 20. These ribs 22 act to entrain a slug punched out of the top layer in the rotary motion of the connecting element so that a welded joint can be made between the slug and the base layer on the front face side.

[0066] FIG. 1A clearly shows that the connecting element 10 is completely hollow. The collar 18 thus extends around an opening 24 which flares axially in a direction opposite to the free end 14 of the shaft 12. In this way, material removed from the top layer is passed through the connecting element 10 during the joining process, thus creating a positive fit between the connecting element and the slug.

[0067] FIG. 2 is a perspective view of the connecting element 10 according to FIG. 1. Seen particularly clearly in the view of FIG. 2 is the opening 24 in the middle of the connecting element 10. This opening 24 fills up completely in the connecting process so that a tight connection is guaranteed. The opening 24 proves to be advantageous especially for connections where no positive connection is established between the connecting element and the base layer.

[0068] The method for producing a component connection will now be described in more detail with reference to FIGS. 5a to 5c.

[0069] FIG. 3, FIG. 3A and FIG. 3B are views of another embodiment of a connecting element 30 according to the invention. FIG. 3A is a sectional view taken along lines A-A of FIG. 1 of connecting element 30. This connecting element 30 substantially corresponds to the connecting element 10 described with reference to FIG. 1. The embodiment of FIG. 3 differs from the one of FIG. 1 in that in this case, the driver structures are not in the form of ribs 22 but in the form of grooves 32. This can be seen particularly well in the cross-sectional view taken along lines B-B through the shaft FIG. 3B.

[0070] FIG. 4 is a view of another embodiment of a connecting element 40, which, as in FIG. 1, has a shaft 42, but the drive 48 is not arranged on a collar 44 but on a head 46 that is provided with the collar 44. In this embodiment, the head 46 forms the end of the hollow-cylindrical shaft 42 at its head-side end, as shown in the sectional view of the connecting element 40 taken along lines A-A of FIG. 4A. In this embodiment, the material cut out of the top layer cannot escape from the connecting element. In this embodiment, the force on the slug is applied via the head 46.

[0071] FIG. 4B is a perspective view of the connecting element 40 illustrating the closed surface of its head 46.

[0072] FIG. 5A to FIG. 5C are exemplary views of the procedural steps of a method for producing a connection between a base layer 52, a top layer 54 and a connecting element 58 according to the invention which is hollow throughout, as seen in FIG. 1, for example.

[0073] The base layer 52 and the top layer 54 are held between an anvil 56 and a setting unit.

[0074] The setting unit comprises a drive tool 60 adapted to drive the connecting element 58 in a rotary motion. At the same time, the drive tool applies an axial contact pressure to the connecting element 58 in the driving direction. The drive tool 60 has a central bulge 61, in particular of a conical shape, which will protrude into the hollow space of connecting element 58 when contacting the latter. This acts to place the connecting element 58 on the top layer 54.

[0075] FIG. 5B is a view of a process step for the production of a component connection according to the invention, in which the connecting element 58 has cut a slug 62 out of the top layer 54 under rotation and contact pressure, which slug is accommodated in the hollow space. The slug is rotated by the driver structures 64, which are arranged within the hollow space, and forms a friction-welded joint with the material of the base layer 52 under contact pressure and rotation.

[0076] FIG. 5C shows the material of the slug 62 rising up as the connecting element penetrates the base layer 52 further. The material rises up to the drive tool 60 where it is laterally displaced by the bulge 61 in the drive tool. As a result, the slug 62 creates a positive connection via the connecting element 58 that is conically recessed at its head end. In this way, a reliable connection is made between the top layer 54 and the base layer 52 via the connecting element 58 and the slug 62.

[0077] FIGS. 6A to 6C show a further embodiment of the method for producing a component connection, which method is similar to the one described with reference to FIGS. 5A to 5C. The component connection comprises a base layer 72, a top layer 74 arranged thereon, and a connecting element 78 according to the invention, in particular according to FIG. 4. The connecting element 78 has a head 80 with a drive, which head 80 forms the end of the hollow shaft 76 of the connecting element 78. The base layer 72 and the top layer 74 are preferably made of aluminum, whereas the connecting element 78 is made of steel. As described above, the connecting element 78 is driven into the top layer 74 in a first cutting stage, preferably at a speed of more than 2,000 rpm, with the contact pressure being preferably less than 3 kN. The slug 82 is thus cut out of the material of the top layer 74 and entrained in the rotary movement of the connecting element 78 by the driver structures that are formed on the inside of the lateral surface, preferably taking the form of ribs extending parallel to the element center axis M, and is then welded to the top layer 74 via its front. Welding is preferably performed at a higher contact pressure than was used in the preceding cutting stage. The contact pressure force applied by the drive tool (not shown here) is transmitted onto the slug 82 via the head of the connecting element.

[0078] Furthermore, FIG. 6C shows the completed connection, with a material connection having been formed between the base layer 72 and the slug 82, for which the connecting element 78 is deformed in that the connecting element 78 penetrates the base layer 72 with the aid of an anvil 84, as in the case of a riveted connection, and is deformed in such a way that the end of the shaft 76 located in the base layer 72 flares outward and thus establishes a form-fit connection in the setting direction between the base layer 72 and the top layer 74. The riveting process is performed in particular using an increased contact pressure.

[0079] The slug 78 connected to the base layer 72 by friction welding thus provides an improved load-bearing capacity of the connection in the direction of shear, i.e. transversely to the setting direction.